Research and development 3D printer Fuse X1

SLSselective laser sinteringfloor-standing

Overview
Fuse X1 makes large‑format industrial SLS 3D printing accessible. Deliver same‑day production‑quality parts at 50% lower cost and 3× the throughput compared to competitors.

Key benefits

• Large‑format production: 330 × 330 × 565 mm build volume with 30%+ packing density for high part counts per build.
• Lower part cost: production‑quality parts for about 50% less and reduced floor space requirements.
• High throughput: same‑day large parts and up to 3× the throughput of competitors.
• Reliable printing: Print Intelligence — an AI‑powered, industry‑first failure prevention system using computer vision and adaptive control to detect anomalies in real time and mask affected areas automatically.
• Fast startup and ease of use: install and operate in one hour; start a print in five minutes.

Performance highlights

• 330 × 330 × 565 mm build volume (61.5 L) — fits large parts and high packing densities for production runs.
• Designed for production workflows: higher packing density, same‑day large parts, and multiple production batch options (from single full‑scale prototypes to thousands of parts/week when scaled).
• Integrated workflow: quick‑connect build chambers, automated powder handling, and compatibility with the Fuse ecosystem for post‑processing (Sift X1, Fuse Blast).

Materials and ecosystem
Supports Formlabs SLS powder materials including Nylon 12 (primary), with planned or upcoming availability for Nylon 11, TPU 90A, Nylon 12 GF and additional powders via Open Material Mode. The Fuse X1 is part of an ecosystem including Sift X1 (powder recovery), Fuse Blast (automated cleaning and polishing), and other post‑processing stations designed for continuous production.

Production workflow

• Prepare: Set up parts and jobs in PreForm to organize builds and material usage across printers.
• Print: Quick‑connect chambers, automated powder loading, and minimal operator intervention; hit print and walk away.
• Unpack: Move build chamber into Sift X1 for contained breakout; integrated glovebox and compressed air aid fast, clean unpacking.
• Clean & Polish: Use Fuse Blast for automated cleaning and polishing; designed for larger parts with ease of removal.
• Refresh & Load Powder: Vacuum Transport System and Mix Kit enable used/new powder handling and reloading for repeat prints.

Technology details

• Adaptive Thermal Control: thermal imaging that collects and processes significantly more thermal data than previous generations, driving multiple independent thermal zones for precise, stable sintering and consistent part quality across builds.
• Print Intelligence: combines computer vision with adaptive temperature control to detect and prevent failures, maximizing yield without sacrificing the rest of the build.
• Insulated build unit, powder transport, dynamic dosing, and a tailored print engine to support industrial throughput and consistent part quality.

Use cases & examples

• Large production batches: illustrative cases include thousands of parts per week with high packing density (examples: drone frames, mixer latches, car door panels, e‑bike frames).
• High‑mix builds, full‑scale prototypes, and end‑use parts for sectors such as automotive, aerospace, manufacturing, and consumer products.

Technical specifications

• Model: Fuse X1
• Build volume: 330 × 330 × 565 mm (13 × 13 × 22.25 in); 61.5 L
• Packing density: 30%+ (typical high‑density production builds)
• Laser type: 120 Watt fiber laser
• Throughput: ~0.330 kg/hr (published throughput metric)
• Print environment: Nitrogen
• Footprint: ~12.2 sq. ft
• Materials: Nylon 12 (primary); planned/support for Nylon 11, TPU 90A, Nylon 12 GF and other 1064 nm powders via Open Material Mode
• Reliability: Print Intelligence (AI‑powered failure prevention), Adaptive Thermal Control with multiple independent thermal zones
• Workflow: Quick‑connect build chambers, automated powder loading, compatible with Sift X1 (powder recovery) and Fuse Blast (cleaning & polishing)
• Installation & operation: Install in ~1 hour; start prints in ~5 minutes
• Starting hardware price (listed): 84,999 (USD)